Services


Consulting regarding industrial robots and robot-based automation

Given the recent technical developments the utilisation of industrial robots is no longer limited to mass and serial production. Also small and medium sized enterprises (SMEs) can deploy industrial robots in economically reasonable ways. In particular robots with payloads of 20 kg or less can be a good option for applications found at SMEs. The benefits that can be generated with robot-based automation depend strongly on the individual use-case. Robots can be used for quality improvements (or to ensure the maintenance of a constant product quality) as well as they can take over monotone or unergonomic tasks. Employees that are freed from repetetive tasks can invest more time in higher qualified, value-added process steps. Through the increase of autonomous run-time of automated machinery (f.i. CNC machines), it is possible to add an additional second (or third) production shift. After the initial installation modern user interfaces often allow robot program alterations or even the introduction of new processes by the end user without external help.

To evaluate, where automation can be used successfully, a thorough analysis of the existing processes is necessary. Depending on the application area the overall system costs can exceed multiples of the initial costs for the robot. Auxiliary system components should not only be defined according to the technical situation inside the robot cell, but also consider the external manufacturing processes and material flow.

Depending on the existing experience of the customer and the planning status of the automated application, different (consecutive) types/ levels of consulting are possible:

  • Initial consulting; discussion of automation potentials within the company. How reasonable is the automation of processes at the customer?
  • Identification of concrete suitable target processes. Analysis of the process requirements and identification of possible critical obstacles for realisation.
  • Consulting during selection of suitable robots and the additional cell componenrs (material-handling technology, image processing, sensor technology, ...).
  • Advice on automation friendly design of products and processes.
  • Training on robot technology and programming (several years of teaching experience).
  • Risk analysis for the robot cell and definition of countermeasures for risk reduction, in particular for applications with human-robot interaction/ fence-less robot applications.

Examples of earlier projects can be found here.

Planning of industrial robot cells

As robotic cells are highly individual products, a comprehensive and thorough planning is imperative to avoid effortful and costly changes of the system afterwards. The transition between consulting and planning phase can be gradual.

  • Selection of suitable robots and auxiliary components.
  • Layout development and optimisation; cycle time analysis
  • Design of grippers, tools, fixtures, etc.
  • Planning, realisation and installation of the necessary eletrical installations
  • Risk analysis according to DIN ISO 12100, DIN ISO 10218, ISO/TS 15066 etc.
  • Definition of measures to ensure all safety requirements
  • Application design for for human-robot collaboration

Robot programming

  • Programming and reprogramming of individual robots and robot cells. Focus on KUKA (Sunrise OS, KRC4, KRC2) robots, but also Universal Robots, Comau, ABB, Yaskawa/ Motoman, Fanuc, Stäubli, etc.
  • Integration of sensor systems, industrial image processing and communication with additional connected devices.
  • Program generation with customers CAM system (strongly depending on used CAM system and existing integration of the robot into the system).

Process data acquisition and processing

By properly deploying the sensor technology integrated in modern robots, process robustness can be increased and quality deviations can already be detected (and possibly corrected) during process execution. This results in cost savings due to less reworking, shorter delivery times and easier ensurance of a consistent product quality. In this context I offer (f.i.) the following services:

  • Examination of the quality requirements - What are the main characteristics determining the product quality and which process parameters can be used to evaluate them respectively?
  • Definition of suitable measurands and measurement methods, as well as conducting test measurements.
  • Process and machine capability studies.
  • Implementation of automated process data processing and analysis and integration into the process sequence.